Middle or large-sized battery module

Abstract

Disclosed herein is a middle- or large-sized battery module comprising: a battery cell stack including a plurality of battery cells or unit modules electrically connected with each other; a first module case constructed in a structure to entirely surround one side end of the battery cell stack and to partially surround the upper and lower ends of the battery cell stack; a second module case coupled with the first module case, the second module case being constructed in a structure to entirely surround the other side end of the battery cell stack and to partially surround the upper and lower ends of the battery cell stack; a sensing member mounted to the first module case or the second module case; and a battery management system (BMS) mounted to the first module case or the second module case.

What is claimed is: 
     
       1. A middle- or large-sized battery module comprising:
 a battery cell stack including a plurality of unit modules connected in series with each other, wherein each unit module includes two or more battery cells constructed in a stacked structure in which electrode terminals of the battery cells are connected in series with each other and electrode terminal connections are bent such that the battery cells are stacked; 
 a first module case configured to surround a side end of the battery cell stack and to partially surround upper and lower ends of the battery cell stack, the first module case being provided at a front part thereof with external input and output terminals; 
 a second module case coupled with the first module case, the second module case configured to surround another side end of the battery cell stack and to partially surround the upper and lower ends of the battery cell stack, the second module case being provided at a front part thereof with bus bars for connecting electrode terminals of the battery cell stack to the external input and output terminals; 
 a sensing member including sensing parts mounted in spaces defined on the front part and a rear part of the second module case and a conduction part for interconnecting the sensing parts; 
 a battery management system mounted to the rear part of the second module case, while being connected to the sensing member, for monitoring and controlling operation of the battery module; and 
 a pair of high-strength cell covers for surrounding outer surfaces of the battery cells excluding the electrode terminals of the battery cells when the cell covers are coupled with each other, 
 wherein the battery module further comprises a front cover mounted to the front part of the second module case for protecting connections between the electrode terminals of the battery cell stack and the bus bars, the front cover being made of an insulative material, 
 wherein the two or more battery cells are plate-shaped battery cells having the electrode terminals formed at upper and lower ends thereof, and 
 wherein the first and second module cases are provided in insides thereof with pluralities of mounting grooves in which edges of the unit modules are inserted. 
 
     
     
       2. The battery module according to  claim 1 , wherein the cell covers are provided at outer surfaces thereof adjacent to upper and lower ends thereof with first steps of a predetermined size for easily fixing the unit modules, and the cell covers are provided at the outer surfaces thereof adjacent to opposite sides thereof with second steps of a predetermined size for easily fixing the unit modules, the mounting grooves of the first and second module cases configured to correspond with the first and second steps. 
     
     
       3. The battery module according to  claim 1 , wherein the second module case is provided at insides of the front and rear parts thereof with pluralities of fixing grooves in which the electrode terminal connections are inserted. 
     
     
       4. The battery module according to  claim 1 , wherein the second module case is provided at the front part thereof with a pair of slits through which the outermost electrode terminals of the battery cell stack are inserted. 
     
     
       5. The battery module according to  claim 4 , wherein the outermost electrode terminals of the battery cell stack are inserted through the slits and then bent such that the outermost electrode terminals are connected to the bus bars located at the front part of the second module case. 
     
     
       6. The battery module according to  claim 1 , wherein an upper end of each bus bar is formed in a shape of a depression such that the external input and output terminals provided at the front part of the first module case are inserted into the depressions of the bus bars when the first and second module cases are coupled with each other. 
     
     
       7. The battery module according to  claim 1 , further comprising:
 a conductive member mounted to at least one of the external input and output terminals for fixing an upper end of the front cover and assisting with connection of a power cable necessary for electrical connection. 
 
     
     
       8. The battery module according to  claim 1 , wherein the front cover is coupled to the second module case in an assembly coupling fashion. 
     
     
       9. The battery module according to  claim 1 , wherein the front cover is provided with holes for fixing a power cable. 
     
     
       10. The battery module according to  claim 1 , wherein the second module case is provided at a lower end of (i) the front part thereof, (ii) the rear part thereof, or (iii) both the front and rear parts thereof with a coupling part which protrudes from the second module case and has a through-hole in a center thereof such that the second module case is fixed to an external device. 
     
     
       11. The battery module according to  claim 10 , wherein the coupling part includes a pair of protruding coupling parts constructed such that one of the protruding coupling parts is higher by a height equivalent to a thickness of the other protruding coupling part than the other protruding coupling part. 
     
     
       12. The battery module according to  claim 1 , wherein the second module case is provided at the rear part thereof with a protruding battery management system receiving part in which the battery management system is received. 
     
     
       13. The battery module according to  claim 1 , further comprising:
 thermistors mounted to the unit modules of the battery cell stack, the thermistors being connected to the battery management system. 
 
     
     
       14. The battery module according to  claim 12 , wherein the battery management system receiving part is provided with a thermistor connector and a communication connector. 
     
     
       15. A middle- or large-sized battery system comprising a plurality of battery modules, wherein each battery module comprises:
 a battery cell stack including a plurality of unit modules connected in series with each other, wherein each unit module includes two or more battery cells constructed in a stacked structure in which electrode terminals of the battery cells are connected in series with each other and electrode terminal connections are bent such that the battery cells are stacked; 
 a first module case configured to surround a side end of the battery cell stack and to partially surround upper and lower ends of the battery cell stack, the first module case being provided at a front part thereof with external input and output terminals; 
 a second module case coupled with the first module case, the second module case configured to surround another side end of the battery cell stack and to partially surround the upper and lower ends of the battery cell stack, the second module case being provided at a front part thereof with bus bars for connecting electrode terminals of the battery cell stack to the external input and output terminals; 
 a sensing member including sensing parts mounted in spaces defined on the front part and a rear part of the second module case and a conduction part for interconnecting the sensing parts; 
 a battery management system mounted to the rear part of the second module case, while being connected to the sensing member, for monitoring and controlling operation of the battery module; and 
 a pair of high-strength cell covers for surrounding outer surfaces of the battery cells excluding the electrode terminals of the battery cells when the cell covers are coupled with each other, 
 wherein the battery module further comprises a front cover mounted to the front part of the second module case for protecting connections between the electrode terminals of the battery cell stack and the bus bars, the front cover being made of an insulative material, 
 wherein the two or more battery cells are plate-shaped battery cells having the electrode terminals formed at upper and lower ends thereof, and 
 wherein the first and second module cases are provided in insides thereof with pluralities of mounting grooves in which edges of the unit modules are inserted. 
 
     
     
       16. An electric vehicle including the battery system according to  claim 15  as a power source. 
     
     
       17. A hybrid electric vehicle including the battery system according to  claim 15  as a power source.